Method of assembling a rotary saw blade with peripheral diamond teeth



1964' 1.. H.'METZGER METHOD OF ASSEMBLING A ROTARY SAW BLADE WITHPERIPHERAL DIAMOND TEETH 0r1g1nal Flled Aug 23 1960 INVEN TOR. LEOPOLDH. METZGER W A-rrv.

United States Patent Ofiice 3,122,03fi Patented Feb. 25, 1964 3,122,030METHGD F ASSEMBLING A ROTARY SAW BLADE WITH PEREPHERAL DIAMOND TEETHLeopold H. Metzger, Glencoe, Ill., assignor to Super-(Int, 1119.,Chicago, ill, a corporation of illinois Continuation of application Ser.No. 51,406, Aug. 23,

1960. This application Aug. 6, 1962, Ser. No. 215,496

3 Gaims. (Cl. 76-112) The present invention relates to rotary stonecutting saws of the type which is commonly employed for sawinglimestone, marble, granite and the like, and has particular reference toa novel method of constructing such saws. The method of the presentinvention comprises forming in a fiat, circular, metallic blade a seriesof equally spaced, circumferentially extending, peripheral notches whichextend inwardly from the circular rim of the blade an appreciabledistance so as to create in the rim a series of heat-dissipating voidswith intermediate rim sections. A series of separately formed,elongated, block-like cutting parts in the form of matrices with diamondparticles therein is then bonded directly to the rim of the blade by theapplication of heat, utilizing a suitable solder or other meltablebonding agent, one cutting part being thus applied to each intermediatepart and bonded thereto throughout its length. This bondin, operation isperformed while the notches are unfilled or open so that each notch willpresent a relatively long, U-shaped, air-exposed edge forheat-dissipating purposes. After the bonding operation, the metal of therim region cools rapidly due to the aforesaid air-exposed edges and,when the metal has sufliciently cooled, a series of flat, metal insertswhich are shaped conformably to the notches, is driven into the notchesto fill the voids created thereby and thus restore the continuity of therim of the blade and place the rim under compression.

Heretofore, when the cutting parts were bonded directly to the unnotchedand continuous rim of the blade, the thermal expansion of metal due toheat caused undesirable buckling of the rim and imparted thereto a wavyconfiguration. The present method obviates such buckling and results ina rim that is truly and continuously fiat.

The present method is applicable to the manufacture of new saws or tothe reconditioning of old saws which have been in service. Inreconditioning an old saw by the present method, the inserts are removedfrom the notches, the old and worn-out cutting parts are then removed bythe application of heat, and new cutting parts, utilizing a heat-bondingoperation, are substituted after which the inserts are replaced.

The method of the present invention is illustrated in the accompanyingsingle sheet of drawing forming a part of this specification.

In this drawing:

FIG. 1 is a fragmentary side elevational view of a rotary stone cuttingsaw which is constructed and assem bled in accordance with theprinciples of the present invention;

FlG. 2 is an enlarged fragmentary perspective View of a portion of thesaw of FIG. 1;

3 is an enlarged sectional view taken on the line 3-3 of FIG. 1;

FIG. 4 is an enlarged sectional view taken on the line 4% of PEG. 1; and

FIG. 5 is an enlarged sectional view taken on the line 5-5 of FIG. 1.

Referring now to the drawing in detail, and in particular to FIGS. 1 and2, a fragment of the peripheral region of a rotary saw for cutting stoneand the like and assembled according to the method of the presentinvention, has been shown and is designated in its entirety by thereference numeral 30. The saw blade 12 is in the form of a relativelylarge, circular, fiat-sided, disk-like member which is formed of steelor other suitable metal. The narrow circular rim 13 of the blade 12 isinterrupted by a series of equally spaced, substantially rectangularnotches 14- which extend radially inwardly of the blade periphery anddefine therebetween intervening rim sections 15. These notches are eachfilled with a steel insert 16, the nature and function of which will beset forth presently. Mounted on the rim 13 of the blade 12 and spanningthe distances between adjacent pairs of notches 14 is a series ofcomposite saw teeth 18, each tool consisting of a pair of spaced steellugs 20 and 22, and an intervening operative cutting part 2 the natureand character of which will likewise be set forth hereafter. Thecomposite teeth 18 project radially outwardly beyond the narrow circularrim 13 and are disposed in circumferentially spaced relationship so thatthey will successively engage the stone or other material undergoingsawing while at the same time a suitable combined liquid coolant andflushing media is applied to the work in the usual manner of operation.

The notches 14 are about as deep as they are wide and the radiallyextending side edges thereof are double bevelled in such a manner thatthey form ribs 26 of V- shape cross section. Each insert 16 is shapedconformably to, and fits within, its respective notch 14 in such amanner as completely to till the same. Accordingly, the side edges ofeach insert 36 are formed with dovetail grooves 28 therealong. Suchgrooves serve to receive the ribs 26 with a tight friction fit. Theinside edge 30 of each insert it; meets th lower edge or bottom 32 ofthe associated notch 14 in coextensive edgeto-edge relationship. Theouter edge 34 of each insert forms a smooth continuation of theinterrupted blade rim 13. The various inserts it? are pressed or forcedinto their respective notches 14 with a tight fit so that the entire rimis placed under compression and, therefore, is rigid. Each insert it; isretained in position by a key-type rivet 35 which extends through acircular hole 38, one-half of the hole being formed in one side marginof the insert and the other half of the hole being formed in theadjacent side edge of the notch 14.

Each composite tooth 18 is comprised of but three parts, namely, the twosteel lugs 20 and 22 and the intervening cutting part 24. The lugs 2%and 22. are each in the form of a wedge-shaped pentahedron having righttriangular side faces 4% and 42, and three rectangular faces consistingof an inner face a front face 46 and a rear face .3. The face 46constitutes an hypotenuse surface. The cutting part 2 3 is in the formof a right angle hexahedron having end faces Si) and 52, side faces 5-:and 56, an outside face 53, and an inside face 6% The cutting part 24consists of a metallic matrix and crushed or fragmented diamondsdistributed substantially uniformly throughout the entire matrix. Theinner faces 44 of the lugs 2i and 22 and the inside face 6% of thecutting part 24 of each composite tooth 18 are curved or arcuate inconformity with the curvature of the rim 13 of the blade 12 in orderthat they fit flatly against the adjacent rim section 15.

The two lugs 20 and 22 are of a width either equal to or slightlygreater than the thickness of the blade 12, while the cutting part 2% issomewhat of greater width than that of the lugs so that it projectslaterally outwardly on opposite sides of the lugs, as best seen in FIG.4. The inner faces 44 of the lugs are bonded directly to the rim 33 ofthe blade 12 by a bonding agent, such as silver solder or by a brazingoperation, so that the rear faces 43 of the lugs 25 and 22 oppose eachother and the transverse edges of the front faces as that are V scribed.

nearer the center of the blade are substantially coincident with theouter ends of the sides of the notches 14. The inside face 6d of eachhexahedral cutting part 24 is similarly bonded to the rim 13 throughoutits entire length so that it spans the distance between the opposed rearfaces 43 of the adjacent lugs and the end faces and 52 of each cuttingpart may be soldered or brazed to said opposed rear faces 48.

In the operation of the aforementioned stone cutting saw, the leadinglugs 20, in addition to forming with the trailing lugs 22 and the rim 13of the blade 12 vise-like pockets or seats for the cutting parts 24,have a twofold purpose. In the first place, they serve, in connectitonwith a stone cutting operation, to absorb any shock which may betransmitted to the leading ends of the composite teeth 16 as a whole.Secondly, they form sludgedcflccting barriers for protecting the leadingends of the cutting parts 24 from the brading action of the sludge whichis created by the cut stone particles and the liquid coolant andflushing material. By forming such barriers, the'lugs 2t) preventundercutting or rapid wearing away of the leading end and side regionsof the cutting parts. The trailing lugs 22 cooperate with the leadinglugs 20 to afford the previously mentioned vise-like gripping action onthe cutting parts 2 and also absorb any pressure which may be exertedthereon by said cutting parts.

According to the method of the present invention, the three parts 29, 22and 24 of each composite tooth are separately and individually formed.Thereafter, these parts are bonded together in the final relationshipwhich they will assume in the assembled saw, i.e., the rear faces 48 ofthe lugs 20 and 22 are bonded to the end faces 50 and 52, respectively,of the cutting part 24. The thus assembled composite saw tooth 18 maythen be bonded as a unit in position on the rim 13 of the blade 12. Alternatively, the separately fashioned parts 24 22 and 24 of each toothmay be individually bonded in position on the rim 13 in any desiredorder of installation and they also may be bonded to one another at anyappropriate time during the installation.

When manufacturing a new saw, the circular disk-like blade blank isfirst notched to provide the series of circumferentially spaced notches14 as previously described.

The composite teeth 18 are then applied in position in any of thealternative methods heretofore described, after which the inserts 16'areinserted in the notches 14 and the secured therein by the rivets 36. Theapplication of the teeth 18 directly to the rim 13 of the blade 12 priorto filling in the interrupted rim region of the blade with the inserts16 constitutes 'one of the principal features of the resent invention.The unfilled notches 14 constitute voids which afford the necessarydegree of heat dissipation during the application of heat to the rim 13in the installation of the composite teeth 18 so that there will be nobuckling or warping of the rim region of the blade. The subsequentfilling in of'the notches 14 with the inserts 16 compresses the metal ofthe rim region of the blade and places the blade'under the proper degreeof compresison so that there will be no fluttering of the rim when thesaw is put into service as previously de- The invention is not to belimited to the precise here- For example, in the manufaccomposite teeth18 is not critical. All of the teeth 18 may be applied to the rim 13before any of the inserts 16 are installed within the notches 14, or,alternatively,

selected regions of the periphery of the blade 12 may be worked upon atappropriate times and in an appropriate sequential manner. Installationof any given insert 16 may be'made atany time after the heat incident tothe tooth bonding operation in the vicinity of the notch in which theinsert is to be installed has been dissipated. Thus, tooth and insertinstallation may be conducted upon the circular blade sequentially in aclockwise or in a counterclockwise direction, or it may be effected atthe will of the operator or operators in localized regions of the bladeperiphery without regard to sequence. The important thing is that agiven composite tooth be applied directly to the rim of the blade priorto installation of the two inserts on opposite sides thereof, with timebeing allowed for cooling of the metal of the blade prior toinstallation of the inserts. Again, for example, it is contemplated thatvarious composite teeth or assemblies 18 may be installed only onalternate rim sections 15 instead of on each and every rim section.Finally, it is not essential to the method that the step or steps ofinstalling either or both steel lugs 20 and 22 be restored to. Some sawswhich are constructed according to the present method and do not employthese lugs have been found in practice to give satisfactory service.

This application is a continuation of United States patent applicationSerial No. 51,406, filed by me on August 23, 1960, now abandoned andentitled Method of Assem ling a Rotary Saw Blade with Peripheral DiamondTeeth.

Having thus described the invention what I claim as new and desire tosecure by Letters Patent is:

1. The method of constructing and assembling a segmental saw for cuttingstone and like material and which comprises providing a substantiallyfiat, circular, metallic blade having a series of equally spaced,circumferentially extending, peripheral notches which extend inwardlyfrom the circular rim of the blade an appreciable distance so as tocreate in the rim region of the blade a series of heat-dissipating voidswith intervening rim sections, separately forming, elongated,block-like, cutting parts in the form of matrices with diamond particlestherein, positioning the cutting parts on said rim sections and so thatthey extend lengthwise of the rim sections and have their inside facesin abutrnent with the peripheral portions of said rim sections, bondingthe inside faces of the cutting parts throughout their entire length tosaid peripheral portions of the rim sections by way of the applicationof heat and while the notches are open or unfilled for heatdissipatingpurposes, fashioning inserts substantially conformably in size and shapeto the size and shape of said peripheral notches, and after bonding inplace of the cutting parts and cooling of the metal of the bladeforcibly driving said inserts into the notches in order to fill thenotches and in addition to render the rim region of the blade continuousand to place the same under uniform compression throughout. 7

2. The method of constructing and assembling a segmental saw for cuttingstone and like material and which comprises providing a substantiallyfiat, circular, metallic blade having a series of equally spaced,circumferentially extending, peripheral notches which extend inwardlyfrom the circular rim of the blade an appreciable distance so as tocreate in the rim region of the blade a series of heatdissipating yoidswith intervening rim sections, separately forming, elongated,block-like, hexahedr'al cutting parts in the form of matrices withdiamond particles therein, of less length than the circumferentialextent of said rim sections, and having rectangular inside faces,rectangular outside faces, oppositely disposed rectangular side faces,

abutment with'the peripheral portions or" said rim sections, bonding theinside faces of the cutting parts throughout'their entire length to'said peripheral portions of the rim sections by way of the applicationof heat'and while the notches. are open or unfilled for heat-dissipatingpurposes, fashioning inserts substantially conformably in size and shapeto the size and shape of said peripheral notches, and after bonding inplace of the cutting parts and cooling of the metal of the blade drivingsaid inserts into the notches in order to fill the notches and inaddition to render the rim region of the blade continuous and to placethe same under uniform compression throughout.

3. The method of constructing and assembling a segmental saw for cuttingstone and like material and which comprises forming in a substantiallyfiat, circular, disklike, metallic blade a series of equally spaced,circumferentially extending peripheral notches which extend inwardlyfrom the circular rim of the blade an appreciable distance so as tocreate in the rim region of the blade a series of heat-dissipating voidswith intervening rim sections, separately forming a pair of identicalmetallic lugs each of which is in the form of a pentahedron having righttriangular side faces, a rectangular inside face, a rectangular frontface and a rectangular back face, separately forming a hexahedralcutting part in the form of a matrix with diamond particles therein andhaving a rectangular inside face, a rectangular outside face, oppositerectangular side faces and rectangular front and back facesrespectively, bonding by the application of heat the inside faces of thetwo lugs to the periphery of one of the rim sections near the leadingand trailing ends thereof respectively in spaced apart relationship,bonding by the application of heat the inside face of the cutting partto the periphery of said one rim section in between the spaced apartlugs and with the front end of the cutting part abutting the back faceof the leading lug and the rear end of said cutting part abutting theback face of the trailing lug, separately fashioning a pair of insertssubstantially conformable in shape to the shape of said peripheralnotches, forcing said inserts into the notches on opposite sidesrespectively of said one rim section, and repeating the lug, cuttingpart and insert forming and mounting operations for each of said rimsegments of the blade.

References Cited in the file of this patent UNITED STATES PATENTS

1. THE METHOD OF CONSTRUCTING AND ASSEMBLING A SEGMENTAL SAW FOR CUTTINGSTONE AND LIKE MATERIAL AND WHICH COMPRISES PROVIDING A SUBSTANTIALLYFLAT, CIRCULAR, METALLIC BLADE HAVING A SERIES OF EQUALLY SPACED,CIRCUMFERENTIALLY EXTENDING, PERIPHERAL NOTCHES WHICH EXTEND INWARDLYFROM THE CIRCULAR RIM OF THE BLADE AN APPRECIABLE DISTANCES SO AS TOCREATE IN THE RIM REGION OF THE BLADE A SERIES OF HEAT-DISSIPATING VOIDSWITH INTERVENING RIM SECTIONS, SEPARATELY FORMING, ELONGATED,BLOCK-LIKE, CUTTING PARTS IN THE FORM OF MATRICES WITH DIAMOND PARTICLESTHERIN, POSITIONING THE CUTTING PARTS ON SAID RIM SECTIONS AND SO THATTHEY EXTEND LENGTHWISE OF THE RIM SECTIONS AND HAVE THEIR INSIDE FACESIN ABUTMENT WITH THE PERIPHERAL PORTIONS OF